ECOsine™ – Passive Harmonic Filters

Schaffner EMV AG Nordstrasse 11 4542 Luterbach Switzerland T +41 32 681 66 26 F +41 32 681 66 30 www.schaffner.com

energy efficiency and reliability

Application Note

ECOsine™ – Passive Harmonic Filters The field guide to harmonics mitigation and energy efficiency

July 2008 1/42

Schaffner EMV AG Application note ECOsine™ – Passive Harmonic Filters Stefan Melly July 2008 2/42

ECOsine™ – Passive Harmonic Filters

The field guide to harmonics mitigation and energy efficiency

Stefan Melly, Business Development Manager

Norbert Häberle, Head of Innovation Center

Andrzej Pietkiewicz, Ph.D., Project Manager Innovation Center

Schaffner ECOsine™ harmonic filters represent an economical solution to the challenge of load-applied harmonics mitigation in three-phase power systems. With a plug-and-play approach and more compact dimensions than comparable products, they can be quickly installed and easily commissioned. They increase the reliability and service life of electric installations, help utilize electric system capacity better, and are the key to meet Power Quality standards such as IEEE Std 519-1992. ECOsine™ filters help to save energy and cut cost.

This application note is intended to support designers, installers, and application engineers with filter selection, installation, application, and maintenance. It provides helpful tips to overcome harmonics mitigation challenges and answers frequently asked questions.

If you require additional support, please feel free to contact your local Schaffner partner.


Important user notice

Schaffner ECOsine™ harmonic filters are designed for the operation on the input (grid) side of power electronic equipment with 6-pulse rectifier front ends in balanced three-phase power systems, like typically used in AC or DC motor drives and high power DC supplies. Filter suitability for a given application must be determined by the user on a case by case basis. Schaffner will not assume liability for any consequential downtimes or damages resulting from use or application of ECOsine™ filters outside of their specifications.

ECOsine™ filters FN 3410 and FN 3412 are not designed for single-phase or split-phase applications.

Important safety considerations

Note: Filter installation has to be carried out by a trained and certified electrician or technician, who is familiar with installation and safety procedures in three-phase power systems.

Warning: High voltage potentials are involved in the operation of ECOsine™ filters. Always remove power before handling energized parts of the filter, and let ample time elapse (> 1 minute) for the capacitors to discharge to safe levels.

Warning: Follow the installation instructions closely. Ensure that fans and cooling slots are free from obstructions that could inhibit efficient air circulation. Do not operate the filter in ambient conditions outside of specifications.

Note: Do not operate ECOsine™ filters on unsymmetrical loads, on linear loads, or with single-phase equipment.

Note: Always use an upstream disconnect or protection device as required by most national and international electric codes.

Note: Always connect the filter to protective earth (PE) first, then continue with the wiring of the trap-disconnect (if needed) and phase connectors.

Note: Follow the Schaffner instructions closely when doing maintenance work. Use exclusively spare parts recommended and approved by Schaffner.

Note: Always practice the safety instructions defined by your company when handling, installing, operating, or maintaining ECOsine™ harmonic filters.

Note: In case of uncertainty and questions please contact your local Schaffner partner for assistance.


Content

1. Part number coding............................................................................................................................... 5

2. Filter description ................................................................................................................................... 6 2.1 General electrical specifications FN 3410 (50Hz filters).................................................................... 6 2.2 General electrical specifications FN 3412 (60Hz filters).................................................................... 7 2.3 Mechanical specifications .................................................................................................................. 8 2.4 Performance characteristics ............................................................................................................ 10 2.5 Function Diagram............................................................................................................................. 13 2.6 External filter elements .................................................................................................................... 14 2.7 Monitoring status.............................................................................................................................. 14

3. Filter purpose and function................................................................................................................ 15

4. Filter selection ..................................................................................................................................... 17

5. Filter application.................................................................................................................................. 20

6. Filter installation.................................................................................................................................. 21

7. Filter maintenance............................................................................................................................... 26

8. Special considerations ....................................................................................................................... 28 8.1 Over-temperature switch and load disconnect ................................................................................ 28 8.2 Trap circuit disconnect..................................................................................................................... 29

9. Application examples.......................................................................................................................... 30 9.1 Harmonics mitigation on an individual motor drive .......................................................................... 30 9.2 Harmonics mitigation in applications with multiple loads in parallel ................................................ 31

10. Troubleshooting ................................................................................................................................ 33

11. FAQ – Frequently asked questions ................................................................................................. 34

12. Custom design input form................................................................................................................ 35

Appendix I: International standards ...................................................................................................... 36 I. Engineering recommendation G5/4-1................................................................................................. 36 II. International standard EN61000-3-12................................................................................................ 38 III. IEEE Std 519-1992 ........................................................................................................................... 41

Appendix II: Declaration of conformity ................................................................................................. 42


1. Part number coding

FN 34xx-xxx-xx

Connection style

33 = safety terminal block 10mm2





99 = copper bus bars

Rated, unfiltered load (drive input) current [A]

Filter family

3410 = filter for 50Hz, 380-500V grids

3412 = filter for 60Hz, 440-480V grids

Schaffner standard filter range

Examples

FN 3410-60-34: Filter for 50Hz, 380-500V grids, 60A drive input current, with 25mm2 terminals

FN 3412-240-99: Filter for 60Hz, 440-480V grids, 240A drive input current, with copper bus bars


2. Filter description

2.1 General electrical specifications FN 3410 (50Hz filters)

Nominal operating voltage: 3x 380 to 500VAC Voltage tolerance range: 3x 342 to 550VAC Operating frequency: 50Hz ±1Hz Network: TN, TT, IT Nominal motor drive input current rating*: 10 to 260A @ 50°C Nominal filter input current rating*: 7Arms to 210Arms @ 50°C Nominal motor drive input power rating: 4 to 160kW Total harmonic current distortion THID**: <5% @ rated power Total demand distortion TDD**: According to IEEE 519, table 10-3 Partially weighted harmonic distortion PWHID: <22% @ rated power Efficiency: >98.5% @ nominal line voltage and power Drive dc-link voltage behavior***: No load: +10% Full load: -5% High potential test voltage****: P --> E 2500VAC (1min) Protection category: IP20 Cooling: Internal forced cooling Overload capability: 1.6x rated current for 1 minute, once per hour Capacitive current at low load: <30% of rated input current, at 400VAC <37% of rated input current, at 500VAC Ambient temperature range: -25°C to +50°C fully operational +50°C to +70°C derated operation***** -25°C to +85°C transportation and storage Flammability class: UL 94V-2 or better Insulation class of magnetic components: H (180°C) Design corresponding to: UL 508, EN 61558-2-20, CE (LVD 2006/95/EC) MTBF @ 50°C/500V (Mil-HB-217F): >200,000 hours Lifetime (calculated): Min. 15 years Safety monitoring functions: Over-temperature of magnetic components Safety monitor output signal: NC switch

* ECOsine™ filters reduce RMS input and peak current by reducing harmonic currents and improving true power factor. ** System requirements: THVD <2%, line voltage unbalance <1% *** Conditions: line impedance <5% **** Repetitive tests to be performed at max. 80% of above levels, for 2 seconds. ***** Iderated = Inominal*√(85°C-Tamb)/35°C


2.2 General electrical specifications FN 3412 (60Hz filters)

Nominal operating voltage: 3x 440 to 480VAC Voltage tolerance range: 3x 396 to 528VAC Operating frequency: 60Hz ±1Hz Network: TN, TT, IT Nominal motor drive input current rating*: 8 to 310A @ 50°C Nominal filter input current rating*: 5Arms to 250Arms @ 50°C Nominal motor drive input power rating: 5 to 250HP Total harmonic current distortion THID**: <5% @ rated power Total demand distortion TDD**: According to IEEE 519, table 10-3 Partially weighted harmonic distortion PWHID: <22% @ rated power Efficiency: >98.5% @ nominal line voltage and power Drive dc-link voltage behavior***: No load: +10% Full load: -5% High potential test voltage****: P --> E 2500VAC (1min) Protection category: IP20 Cooling: Internal forced cooling Overload capability: 1.6x rated current for 1 minute, once per hour Capacitive current at low load: <30% of rated input current, at 460VAC Ambient temperature range: -25°C to +50°C fully operational +50°C to +70°C derated operation***** -25°C to +85°C transportation and storage Flammability class: UL 94V-2 or better Insulation class of magnetic components: H (180°C) Design corresponding to: UL 508, EN 61558-2-20, CE (LVD 2006/95/EC) MTBF @ 50°C/460V (Mil-HB-217F): 200,000 hours Lifetime (calculated): Min. 15 years Safety monitoring functions: Over-temperature of magnetic components Safety monitor output signal: NC switch

* ECOsine™ filters reduce RMS input and peak current by reducing harmonic currents and improving true power factor. ** System requirements: THVD <2%, line voltage unbalance <1% *** Conditions: line impedance <5% **** Repetitive tests to be performed at max. 80% of above levels, for 2 seconds. ***** Iderated = Inominal*√(85°C-Tamb)/35°C


2.3 Mechanical specifications


0

1

2

3

4

5

6

7

8

0 20 40 60 80 100 120 140 160

Load [%]

THID

[%]

Z line=0.2%Z line=3.0%

2.4 Performance characteristics

THID vs. load

Individual harmonics with/without filter

0

1 0

2 0

3 0

4 0

5 0

6 0

7 0

8 0

9 0

1 0 0

1 5 7 1 1 1 3 1 7 1 9 2 3 2 5 2 9 3 1 3 5 3 7H a r m o n ic

V a lu e [% ]

W ith o u tW ith


TDD vs. load

0

1

2

3

4

5

0 20 40 60 80 100 120 140 160

Load [%]

TDD

[%]

Demand=200%Demand=100%

Demand=100%: means that maximum demand at PCC is equal to 100% of maximum fundamental component of nonlinear load;

Demand=200%: means that maximum demand at PCC is equal to 200% (100% nonlinear load + 100% additional linear load)

Power factor vs. load

0.00

0.20

0.40

0.60

0.80

1.00

1.20

0 20 40 60 80 100 120 140 160

Load [%]

CO

S (p

hi)

Z line=0.2 to 3.0%


Drive dc-link voltage vs. load

460

480

500

520

540

560

580

600

620

0 20 40 60 80 100 120 140 160

Load [%]

U d

c lin

k [V

dc]

Z line=0.2% Z line=3.0%UmaxUnomUmin


2.5 Function Diagram

Filter terminals Line 3 touch safe terminal blocks (busbar terminals >240A) Load 3 touch safe terminal blocks (busbar terminals >240A) Monitor NC switch, 250VAC/3A, touch safe terminal 4mm2 Open position indicates error PE Protective earth. Threaded stud with washer and nut Trap disconnect Touch safe terminals. Upon delivery, wire bridges are

installed for immediate operation of the filter. They allow for the connection of an external contactor for load dependent disconnection of the trap circuit, if needed.

Function blocks Chokes Power magnetic components incl. temperature sensors Capacitors Power capacitors incl. discharge resistors Fan Field replaceable fan for choke cooling Power supply Internally generated 24VDC for fan supply Control Temperature monitoring Monitor switch triggering LED readout


2.6 External filter elements

Line terminals (3) Cap disconnect terminals (6) LEDs (3) Load terminals (3)

PE terminal (1) Fan Monitor switch (2)

2.7 Monitoring status

LEDs Monitor switch Filter state

Power off

Power on, internal temperature does not require fan

Power on, active fan cooling

Power on, over-temperature or fan error *

Power on, sensor short or monitor error

* Fan or sensor disconnection is recognized


3. Filter purpose and function

ECOsine™ harmonic filters are based on passive LCR filtering technology. They are intended for the operation on the input side of balanced three-phase 6-pulse rectifiers, like commonly used in inverters for motor drives.

ECOsine™ Motor drive Motor

6-pulse rectifiers inherently draw current in a non-sinusoidal fashion from the grid, creating a current wave form rich in harmonics. Harmonic currents flow through system impedances and create harmonic voltages. Both harmonic currents and voltages give raise to serious issues, such as electric system overload, reliability problems, and violations against international standards and utility codes.

ECOsine™ filters efficiently reduce the harmonic currents to negligible levels and ensure, that a sine-wave current is drawn from the grid. In the process, they also reduce peak currents and RMS input current, allowing for lower wire cross sections in conductors, smaller fuses, breakers, and transformers. In existing installations, more drives can be used on the same distribution transformer.

The example on the next page visualizes typical performance test results with and without a Schaffner ECOsine™ harmonic filter FN 3410-13-44 for the same real load power of 6kW.

M3~


Without ECOsine™ filter With ECOsine™ filter

Voltage and current waveforms

Voltage and current waveforms

Current harmonics THD = 164.3% (scale 0-100%)

Current Harmonics THD = 4.0% (scale 0-10%)

Power, PF, Cosφ, Current Power, PF, Cosφ, Current


4. Filter selection

ECOsine™ harmonic filters need to be carefully selected in order to enjoy maximum benefits.

Step 1: grid frequency Determine, whether the system in question will be operated in a 50Hz or 60Hz electricity grid, and select the corresponding filter range according to the following table:

50Hz grid Europe, Middle East, parts of Asia, parts of South America Use FN 3410

60Hz grid North and Central America, parts of Asia, parts of South America Use FN 3412

Note: a 50Hz filter will not provide satisfying harmonics mitigation in a 60Hz grid, and vice versa.

Step 2: grid configuration Verify, that the grid configuration is suitable for standard ECOsine™ harmonic filters according to the following table:

50Hz grid Nominal voltage 380-500VAC ±10% TN, TT, IT configuration

60Hz grid Nominal voltage 440-480VAC ±10% TN, TT, IT configuration

Note: Filters for 600V/60Hz or 690V/50Hz, as well as single-phase filters, are available upon request.

Step 3: real rectifier/drive input power The individual filter must be selected by the actual rectifier/drive input real power (kW, HP). It is important to select the filter as close as possible to the effective input power of the rectifier/drive.

Note that FN 3410 (50Hz) filters show double ratings in the selection table. Depending upon the grid voltage, the same filter is rated for two different rectifier/drive input real power values. For 380/400/415V lines, the filters have a lower power rating than for 500V systems.

Note that if the rectifier/drive is being operated very close to its rated power, then the filter can be selected by the motor drive’s nominal power rating. However, if the drive will be operated e.g. at only 66% of its rated power, then a smaller filter should be selected in order to get maximum harmonics mitigation performance and the optimum in terms of cost, size, and weight.

Please refer to the following examples:

Example 1: Power line rating: 400V, 50Hz Drive rating: 380-500V, 50-60Hz, 15kW, 22.5A Planned rectifier/drive input real power: 15kW (100% of drive rating)

Recommended filter according to the filter selection table FN3410: Type FN 3410-32-33








Overrating the filter does never make sense, because of the inherent lower harmonics mitigation performance at light load, as well as higher price, size, and weight.

Please refer to the selection tables on the next page.


Filter selection table FN 3410 (50Hz)

Filter selection table FN 3412 (60Hz)


5. Filter application

ECOsine™ filters are designed as “load-applied” filters. In contrary to “bus-applied” filters, which are being installed e.g. at the main power bus of a building, they are specifically designed to be used with either an individual non-linear load, or with a group of non-linear loads.

One advantage of load-applied filtering is the fact that the upstream power (relative to the harmonic filter) is clean. This can be of vital importance when the same power bus supplies both motor drives and sensitive loads. One example could be the elevator drives or HVAC drives in a hospital, where power must be very clean for all the sensitive medical devices. In such a case, it would not be sufficient to use a central harmonic filter at the PCC for IEEE Std 519-1992 compliance purposes.

ECOsine™ filters are also suitable for paralleling lower power non-linear loads on a higher power harmonic filter to improve overall system economy. In this case the total expected load power of all connected drives must match the filter.

If the expected input power exceeds the rating of the largest available filter, and a custom solution is not desired, then two or more filters can be wired in parallel. In this mode of operation, it is recommended to use filters with equal power ratings to ensure proper current sharing.

AC line reactors and/or dc-link chokes are not required when ECOsine™ filters are installed. For a new system, this situation helps to offset a good portion of the harmonic filter cost. If a harmonic filter is added to a drive with an existing AC line reactor, it is recommended to remove the reactor if possible.


6. Filter installation

Please follow the few simple steps below to ensure a safe and satisfying filter function for many years.

Step 1: Visual inspection All Schaffner ECOsine™ filters have undergone rigorous testing before they left our ISO9001:2000 certified factory. They are packaged with great care in a sturdy container for international shipment.

However, carefully inspect the shipping container for damage that may have occurred in transit. Then unpack the filter and carefully inspect for any signs of damage. Save the shipping container for future transportation of the filter.

In the case of damage, please file a claim with the freight carrier involved immediately and contact your local Schaffner partner for support. Under no circumstances install and energize a filter with visible transportation damage.

If the filter is not going to be put in service upon receipt, store within the original container in a clean, dry location, free of dust and chemicals.

Step 2: Mounting ECOsine™ load-applied filters are best installed as close as possible to the non-linear load in question. Ideally they are mounted next to the rectifier or motor drive inside the electrical cabinet or control room.

ECOsine™ comes in two designs, depending on their size:

FN 3410 Filters from 10 to 110A For vertical wall mounting

FN 3410 Filters 150A and up For upright floor mounting

FN 3412 Filters from 8 to 130A For vertical wall mounting

FN 3412 Filters 160A and up For upright floor mounting

Note: Filters for vertical wall mounting must not be installed horizontally. Horizontal installation will negatively affect air flow and the life time of the filter.

Important:

In order to ensure sufficient air flow, keep a clearance of min. 150mm above and below the filter to walls or other components. A 20mm clearance on either side is recommended for the possibility to open the cover in case of maintenance requirements.

It must be ensured that the environmental temperature is kept below 50°C with appropriate thermal management (e.g. cabinet cooling). Filter operation in warmer environments require temperature derating.

EC

Osi

ne™

Driv

e

>150mm

>150mm

>20mm


2.1 Screw hole positions for wall mounted filters:

FN 3410 FN 3412 H W D

-10, -13 -8, -11 380 130 M6

-16 -15, -21 410 170 M8

-24, -32, -38 -28, -35, -41 495 200 M10

-45, -60 -53, -65 565 240 M10

-75, -90, -110 -80, -105, -130 725 270 M10

All dimensions in mm; 1 inch = 25.4mm

2.2 Screw selection: Schaffner recommends zinc coated hex ribbed flange steel bolts. Respect filter weight for appropriate choice of screws! Head diameters must not exceed these dimensions:

M6: d ≤ 14.2mm, M8: d ≤ 18.2mm, M10: d ≤ 21.2mm

2.3 Filter placement:

1. Set screws loose into wall, leave 5mm distance from head to wall.

2. Lift filter with appropriate crane, using lifting eye bolt (attached in package) – smallest types (up to 20kg) may be lifted manually by two persons (no lifting eye bolt applicable).

3. Place filter first onto lower screws ...

4. ... then position it through backplane head openings on upper screws.

5. Fix screws with appropriate torque (depending upon the material of the back plane and local standards).

2.4 Filter types FN 3410-150, FN 3412-160 and above are floor mounting (upright) designs. It is recommended to bolt them permanently to the floor with four screws. Screw hole positions:

FN 3410 FN 3412 A B D

-150, -180, -210

-260

-160, -190

-240, -310

336 240 M12

All dimensions in mm; 1 inch = 25.4mm

H

W

D

d

3.

4.

D

B

A


2.5 Important:

Handling of floor mounting designs: Use lifting eye bolts, which can be fixed on both sides of the filter. Caution has to be taken because of high product weight.

Never attempt to handle the filter with a forklift (once it is unpacked) by placing the fork between filter legs. This procedure can tip over the filter and/or damage the base of the filter.


Step 3: Wiring

3.1 Verify safe disconnection of all line side power.

Consult your local safety instructions.

3.2 Carefully connect protective earth (PE) wire to adequate earth potential close to ECOsine™ filter.

Use a wire diameter of equal or bigger size as foreseen for line/load side power cables – according to your local codes and safety instructions.

3.3 Connect PE wire on lower left side of ECOsine™

with appropriate cable lug to threaded stud.

max. torque M6: 14Nm



3.4 Connect ECOsine™ load side terminals L1’, L2’, L3’ to respective motor drive or rectifier inputs.

Last two digits of ECOsine™ part number, i.e. FN 3412-65-34, indicate terminal type. See table to the right for recommended wire size and torque.

Use stranded copper wire with a temperature rating of 75°C or higher.

3.5 Use wired trap circuit (default) or install external capacitive current control.

Terminals A1-A2, B1-B2 and C1-C2 are delivered with installed jumpers. When interconnected via an external capacitor contactor (not supplied by Schaffner), they allow for load dependent disconnection of the trap circuit, if needed. Thus capacitive current can be minimized for low load operation. Estimation of required contactor size: see box to the right.

USE ONLY CAPACITOR CONTACTORS FOR MINIMIZATION OF INRUSH CURRENT. OTHERWISE CAPACITOR LIFETIME MAY BE REDUCED.

Terminal Wire Torque

AWG mm2 Nm -44 8 6 1.0 - 1.2

-33 6 10 1.5 - 1.8

-34 2 25 4.0 - 4.5

-35 1/0 50 7.0 - 8.0

-40 4/0 95 17 - 20

-99 6/0 150 25 - 30

ECO

sine

™

D

rive

>150mm

>150mm

>20mm

Contactor performance estimate:

Example: FN 3412-65-34

Divide rated load current by 2, multiply with nominal 3-phase voltage, i.e. 460VAC

(65/2 * 460 = ~15kVAR)


3.6 Connect monitor switch

The monitor switch is a relay contact, which is open in OFF and ALARM state. Its load rating is 250VAC/30VDC/3A. It may either be used to remotely disconnect the drive's load via respective input of drive control (check drive manual) or as alarm sensor for system control unit.

AN ENGAGED MONITOR SWITCH MUST LEAD TO IMMEDIATE LOAD SHUTDOWN AND INVESTIGATION OF THE PROBLEM.

3.7 Connect ECOsine™ line side terminals L1, L2, L3 to power input protection (typically circuit breakers).


7. Filter maintenance

Schaffner ECOsine™ filters are reliable low maintenance products. Many products like power supplies, inverters, or motor drives utilize fans for forced cooling to minimize the size and weight. ECOsine™ filters are designed with a similar temperature management concept and therefore, fans may have to be maintained and replaced in certain intervals to sustain the function and value of the product. Fans are 100% field replaceable without the need to uninstall and disconnect the filter.

LINE SIDE POWER MUST BE SWITCHED OFF PRIOR TO REPLACEMENT OF FAN.

Warning:

Power electronic devices like motor drives contain large capacitors which may retain perilous charges for a period of time. Before opening the cabinet or device, disconnect the supply power and let ample time elapse (> 1 minute) for the capacitors to discharge to safe levels. Use a meter to check terminal voltages before touching or handling!

Maintenance considerations:

Schaffner harmonics filters are equipped with long life components that ensure a satisfactory function for many years under normal operating conditions. Any operation under extreme conditions such as over-temperatures, overvoltage situations, polluted environments etc. reduces the life expectancy.

Under normal operating conditions (ambient temp at 25°C) and with the filter permanently charged at full load, the fan(s) will typically have 50% duty cycle. This translates roughly to a 10 year maintenance-free life time.

Nevertheless, it is recommended to check the functionality at least in a 2 year intverval, when a 'normal 100% load' situation is given. More severe operating conditions may require shorter service intervals.

Indications for required fan replacement: - increased audible noise coming from the fan - after 50,000 hours fan ON state.

Power capacitor damage may be caused by severe abnormal supply voltage peaks (i.e. lightning – depending upon system protection), but may only be recognizable through the measurement of line side harmonics distortion. This may be indicated with a modern energy meter or by regular checkup with a distortion analyzer. According to the above considerations, a 2 year inspection interval is advisable. An inspection should as well be performed after extreme overvoltage situations.

Field replacement of power capacitors is possible, but must be executed by trained Schaffner personnel.

Indications for required capacitor replacement: - performance loss (THID out of spec) - visible capacitor damage


Fan specifications:

Supply voltage: 24VDC

Power: max. 7W

Size 1*: 92x92x25mm, fixation holes 82.5x82.5mm, Ø4.3mm

Size 2*: 120x120x25mm, fixation holes 105x105mm, Ø4.3mm

Air flow (size 1): min. 70 CFM (cubic feet per minute / 1 CFM = 1.7m3/h)

Air flow (size 2): min. 110 CFM

Connection: min. 150mm cable length, TYCO MTA-100 plug, 2 poles (pin 1 = +24VDC)

Recommended types (Size 1):

SUNON PMD2409PTV1-A / KD2409PTBX-6A NMB-MAT 3610KL-05W-B50

Recommended types (Size 2):

SUNON PMD2412PTB3-A NMB-MAT 4710KL-05W-B50

* Size 1: FN 3410-10-44; FN 3410-13-44; FN 3412-8-44; FN 3412-11-44

Size 2: all other filters

Fan replacement instructions:

1 Disconnect line side power. Consult your local safety instructions.

2 Unscrew fan plate on bottom side of filter.

3 Pull out fan connector plug.

4 Disassemble fan from plate (4 bolts).

5 Mount a new fan with appropriate plug (isolation tube and plug of old fan may be used again; appropriate tool for IDC connection needed). Pay attention to the polarity of the plug.

6 Connect fan to plug socket, re-assemble fan plate.

Step 2 Step 3 Steps 4, 5


8. Special considerations

8.1 Over-temperature switch and load disconnect

FN 3410/FN 3412 harmonic filters provide advanced safety monitoring:

two temperature detection levels for each inductive component (fan activation level, over-temperature indication level)

monitoring of temperature sensor impedance (too low - short - and too high - open - impedance trigger monitor switch)

fan operation monitoring (too low fan current or fan supply voltage are recognized and trigger monitor switch).

All these alarm indications request adequate reaction in order to prevent possible system damage (i.e. cable or cabinet overheating). Either the cabinet safety monitoring unit will make use of the alarm switch, or the switch can directly control a stop function of a connected motor drive (refer to drive manual for applicability).

Technical data of monitor switch:

Error status: Switch open

Switching power: max. 3A/250VAC or 30VDC

min. 10mA/5V

Technology: Mechanical switch (relay, potential-free)

Safety: UL 508

Note: The described applications of the monitor switch are proposals. Please respect local and national safety prescriptions.

Note: Open switch state is identical to non-powered state, thus safety monitoring unit must override monitoring signal during power-on or restart.


8.2 Trap circuit disconnect

The trap circuit disconnect feature is built-in for the purpose of reducing the capacitive current during low load operation, if needed. With permanently connected trap circuit, cos(phi) vs. load shows following characteristics:

0.00

0.20

0.40

0.60

0.80

1.00

1.20

0 20 40 60 80 100 120 140 160

Load [%]

CO

S (p

hi)

Z line=0.2 to 3.0%

When the trap circuit is disconnected, cos(phi) returns to ~0.98. At the same time, the THID will increase. This may be negligible, since absolute values are low due to reduced load power. Required external components (not part of ECOsine™ filter) or system functions for fully automated capacitive current control:

motor load (power factor) monitoring device

capacitor contactor

A reduced load system status may be available as system controller output signal. In this case, only adequate driving of capacitor contactor has to be assured.

Note: it is necessary to take into account overall concept of power factor correction. A system PFC correction unit with large capacitor banks may become obsolete or massively reduced, when harmonic filters are installed. In such cases it may not be necessary to install trap circuit disconnect functions.

Recommended settings:

Schaffner recommends to engage and disengage the trap circuit disconnect at following load levels:

Trap circuit status Proposed load level

Dis-connect When load level drops under 10-15%

Connect When load level rises above 20-25%


9. Application examples

9.1 Harmonics mitigation on an individual motor drive

Problem: A 5.5kW motor drive is used in the well head control system of a small scale oil exploration site. The drive is controlling the motor of a submersible pump down in the well. It is designed to run close to full load for the most part. The well head control unit has to meet IEEE Std 519-1992. The existing harmonic spectrum is significantly above acceptable limits.

Mains

Motor drive: 5.5kW / 480VAC

Motor

Measurements without filter:

Current: Iin = 11Arms (for power 5.5kW) THID = 92% (Rsce = 150) PWHD = 37%

Voltage: Uin = 480Vrms (phase-phase) THVD = 4.4% (for Isc/IL = 150)

0

20

40

60

80

100

Irms 5th 7th 11th 13th

[%]

No f ilter

Solution: ECOsine™ FN 3410-10-44 is the appropriate harmonic filter to match both the system specifications and the load rating. Ideally, the filter is installed close to the motor drive, potentially next to it on the back wall of the cabinet.

ECOsine

FN3410-10-44Motor drive: 5.5kW / 480VAC

Mains

Motor

Measurements with filter:

Current: Iin = 7.5Arms (for power 5.5kW) THID = 4.0% (Rsce = 150) PWHD = 5.2%

Voltage: Uin = 480Vrms (phase-phase) THVD = 0.12% (for Isc/IL = 150)

0

20

40

60

80

100

Irms 5th 7th 11th 13th

[%]

No f ilter Filter


9.2 Harmonics mitigation in applications with multiple loads in parallel

Problem: An office building is operating 3 HVAC systems in parallel, involving drives and motors of different power rating. On average, the drives are running at 85% of rated power. The resulting harmonic distortion is causing crashes of the in-house IT infrastructure. In addition, the entire factory does not meet the IEEE Std 519-1992 requirements at the point of common coupling PCC (TDD 102.5%). The use of an active harmonic filter at the main building bus has already been evaluated, but it is out of the question for cost reasons. The project manager has to determine the best yet affordable solution.

Potential solution 1: The first attempt of the project manager is the installation of 1 ECOsine™ harmonic filter type FN3410-180-40 (400V, 50Hz, 90kW) upstream of the 100kW drive, loaded with 85%.

Public grid400VAC, 50Hz

PCC

Building supply100kWDrive

18.5kWDrive

30kWDrive

M

M

M

Group of sensitive IT equipment

FN3410-180-40

Trying to utilize the harmonic filter at the biggest non-linear load is a good idea, but not sufficient in this case. The TDD at the PCC after the installation of FN3410-180-40 is 24.3%. System loading parameters ask for a TDD of max. 8% according to IEEE Std 519-1992.

Potential solution 2: In order to overcome the problem above, additional filters upstream of the lower power drives can be installed. A good choice is FN3410-60-34 (400V, 50Hz, 30kW) for the 30kW drive and FN3410-32-33 (400V, 50Hz, 15kW) for the 18.5kW drive (both loaded 85%).


PCC


18.5kWDrive

30kWDrive

M

M

M


FN3410-180-40

FN3410-60-34

FN3410-32-33

TDD: 24.3%

TDD: 4.8%


Adding these harmonic filters results in 4.8% TDD at the PCC, and thus IEEE Std 519-1992 is fulfilled. However, adding a total of 3 filters to the system may not be the most economic solution, so the project manager considers yet another option.

Potential solution 3: instead of adding a filter to each drive, 1 higher power ECOsine™ harmonic filter with the following ratings is added: FN 3410-260-99 (400V, 50Hz, 132kW). The total load real power of the 3 drives running in parallel at 85% is 126kW.


PCC


18.5kWDrive

30kWDrive

M

M

M


FN3410-260-99

The measured result at the PCC after the implementation of above measures in now a TDD of 5.1%, and

thus the building is still well within the IEEE Std 519-1992 requirements. An economic and technical

analysis including filter price and installation time results in the conclusion that solution number 3 will be

chosen for this particular case.

TDD: 5.1%


10. Troubleshooting

Schaffner ECOsine™ harmonic filters are high quality products and have undergone rigorous testing and qualification procedures. Every unit runs through a 100% test in our ISO9001:2000 factories. There are no troubles to be expected if the filter is installed, operated, and maintained as described in this document.

In the unlikely event of a problem, please contact your local Schaffner partner for assistance.


11. FAQ – Frequently asked questions

Q: Why are ECOsine™ harmonic filters CE-marked, but Schaffner EMI filters are not?

A: EMI filters and other passive components must not be CE-marked according to the low-voltage directive because they are not sold to the public as an individual device with an independent function. They are usually part of an equipment, which in turn has to be CE-marked as a whole. This is different with e.g. a transformer or a harmonic filter. ECOsine™ can be sold as an individual aftermarket product that will not necessarily be built into another CE-conform piece of equipment. As a “stand-alone unit”, it must be CE-marked in order to be distributed throughout Europe.

Q. Can ECOsine™ filters be used for a single-phase load or just be connected to two phases?

A: This mode of operation is not possible. ECOsine™ filters are optimized for balanced three-phase power systems with 6-pulse rectifier front ends and their performance depends upon voltage distortion and phase unbalance. Schaffner is experienced in custom harmonic filter design and can potentially come up with a single-phase solution to your requirement.

Q:

A:


12. Custom design input form

There may be occasions where ECOsine™ standard filters are not suitable for the job at hand. Schaffner is very experienced in the design and manufacturing of custom filters based on the existing modular ECOsine™ platform and can potentially come up with an alternative design proposal for you.

Custom harmonic filters include (but are not limited to) solutions for higher power ratings, higher voltage ratings, different performance levels, or special mechanical designs.

Please use the following table to gather essential technical information prior to contacting your local Schaffner partner.

Application incl. power system:

Types of non-linear loads:

System block schematic:

Current harmonic spectrum:

Required harmonics reduction (THID, TDD, standard):

Expected total load real power: [kW], [HP]

Expected total input current: [A]

System voltage: [VAC]

System frequency: [Hz]

Efficiency: [%]

Overload capability: [%]

Max. capacitive current: [%], [A]

Ambient temperature: [°C]

Expected life time: [h]

Mechanical requirements:

Terminals:

Safety approvals:

Monitoring functionality:

Other special requirements:


Appendix I: International standards

The use of non-linear loads with 6-pulse rectifiers has grown rapidly in recent years, to the point where this type of load represents more than 50% of western world power system load. Harmonic currents and the resulting voltage distortions can have devastating effects on power distribution systems and connected equipment. Therefore, national and international standards for harmonic distortions (and other Power Quality problems) are needed.

In the following, a brief overview of some important international standards/recommendations are provided. For full details, please obtain the required standards directly from IEEE, IEC, and other organizations.

I. Engineering recommendation G5/4-1

Definitions:

Non-linear load or equipment A load or equipment that draws a non-sinusoidal current when energized by a sinusoidal voltage.

Aggregate load Non-linear load equal to the sum of the individual non-linear equipment ratings.

Fault level A value expressed in MVA of the symmetrical short-circuit power at a point in the supply system. It is defined as the product of the symmetrical short-circuit current (Isc) and the nominal system voltage (Uph-ph or Uph-n):

Harmonic current (Ih) The RMS value of a harmonic current, of order h, expressed in amperes.

Harmonic distortion The cyclic departure of a waveform from the sinusoidal shape. This can be described by the addition of one or more harmonics to the fundamental.

Point of common coupling (PCC)

The point in the public supply system, electrically nearest to a customer’s installation, at which other customers’ loads are, or may be, connected.

Total harmonic voltage distortion (THD)

33 ⋅⋅=⋅⋅= −− nphscphphsc UIUIF

21

50

2

2

V

VTHD

h

hh∑

=

==


G5/4-1 planning levels for harmonic voltages:

G5/4-1 current harmonic limits for loads rated >16A per phase:


II. International standard EN 61000-3-12

This standard applies to equipment intended to be connected to low-voltage systems interfacing with the public supply at the low-voltage level. It does not apply to equipment intended to be connected only to private low-voltage systems interfacing with the public supply only at the medium- or high-voltage level.

Definitions:

Total harmonic distortion (THD)

Ratio of the r.m.s. value of the harmonics (harmonic currents In of the order n) to the r.m.s. value of the fundamental:

Partial weighted harmonic distortion (PWHD)

Ratio of the r.m.s. value of a selected group of higher order harmonics (in this International Standard beginning from the fourteenth harmonic), weighted with the harmonic order n, to the r.m.s. value of the fundamental:

Reference fundamental current (I1)

r.m.s. value of the fundamental component of the rated line current Iequ of the equipment. The reference fundamental current I1, shall be either measured, or calculated as follows:

Total harmonic current (THC)

The total r.m.s. value of the harmonic current components of orders 2 to 40:

Point of common coupling (PCC)

The point in the public system which is closest to the customer concerned, and to which other customers are, or may be, connected.

Short circuit power (Ssc) Value of the three-phase short-circuit power calculated from the nominal interphase system voltage Unominal and the line impedance Z of the system at the PCC:

where Z is the system impedance at the power frequency.

Rated apparent power of the equipment (Sequ)

Value calculated from the rated line current Iequ of the piece of equipment stated by:

Short circuit ratio (Rsce) Characteristic value of a piece of equipment defined as follows:

II

nn

THD1

40

2

2∑==

∑=

=⎟⎟⎠

⎞⎜⎜⎝

⎛⋅=

40

14

2

1

n

n

n

IInPWHD

211 THD

II equ

+=

∑=

=40

2

2

nnITHC

ZUS nomsc2=

equiequ IUS ⋅⋅= 3

equscsce SSR =


EN 61000-3-12 current harmonic limits:

Conditions to use Table 4:

1. The phase angle of the 5th harmonic current related to the fundamental phase voltage is in the range of 90° to 150°. Note: This condition is normally fulfilled by equipment with an uncontrolled rectifier bridge and capacitive filter, including a 3% AC or 4% DC reactor.

2. The design of the equipment is such that the phase angle of the 5th harmonic current has no preferential value over time and can take any value in the whole interval (0°…360°). Note: This condition is normally fulfilled by converters with fully controlled thyristor bridges.

3. The 5th and 7th harmonic currents are each less than 5 % of the reference fundamental current.


Interpolation of current harmonic limits:

Product documentation according to EN 61000-3-12:

For equipment complying with the harmonic current emission limits corresponding to Rsce = 33, the manufacturer shall state in his instruction manual or literature:

”Equipment complying with IEC 61000-3-12”

For equipment not complying with the harmonic currents emission limits corresponding to Rsce = 33, the manufacturer shall:

determine the minimum value of Rsce for which the limits given in Table 3 or 4 are not exceeded,

declare the value of the short-circuit power Ssc corresponding to this minimal value of Rsce in the equipment instruction manual

and instruct the user to determine, in consultation with the distribution network operator, that the equipment is connected only to a supply of that Ssc value or more. For that purpose, the statement in the instruction manual shall be:

"This equipment complies with IEC 61000-3-12 provided that the short-circuit power Ssc is greater than or equal to xx at the interface point between the user's supply and the public system. It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment is connected only to a supply with a short-circuit power Ssc greater than or equal to xx."

where xx is the value of Ssc corresponding to the minimum value of Rsce for which the limits given in Table 3 or 4 are not exceeded.


III. IEEE Std 519-1992

Table 10-3 lists the harmonic current limits based on the size of the load with respect to the size of the power system to which the load is connected. The ratio Isc/IL is the ratio of the short-circuit available at the point of common coupling (PCC), to the maximum fundamental load current.

IEEE Std 519-1992 also introduces the total demand distortion (TDD), the harmonic current distortion in % of maximum demand load current (15 or 30 min demand).

The limits listed in Tables 10-3, should be used as system design values for the worst case for normal operation (conditions lasting longer than one hour). For shorter periods, during start-ups or unusual conditions, the limits may be exceeded by 50%.

Table 10-3: current distortion limits for general distribution systems (120V through 69000V):

Other standards:

ECOsine™ harmonic filters are perfectly suitable to fulfill the most stringent requirements of IEEE Std 519-1992 or EN 61000-3-12. They also fulfill the requirements of other standards, like e.g. EN 12015 for elevators and escalators. However, because of different/relaxed limits, simpler filters may be sufficient for the job. Schaffner has already designed many engineered harmonic filters for relaxed requirements and may be able to quickly offer you a custom product that perfectly matches the requirements of an application.


Appendix II: Declaration of conformity

Manufacturer: Schaffner EMV AG

Nordstrasse 11 CH-4542 Luterbach Switzerland

Declares, under the sole responsibility, that the following product: Products: ECOsine™ FN 3410 range

ECOsine™ FN 3412 range Options: all is in conformity with the following directives and standards: Directives: Low voltage directive 2006/95/EC

EMC directive 2004/108/EC Standards: EN 61558-1:2005 Sicherheit von Transformatoren, Netzgeräten,

Drosseln und dergleichen -Teil 1: Allgemeine Anforderungen und Prüfungen

EN 61558-2-20:2000 Sicherheit von Transformatoren, Netzgeräten und dergleichen -Teil 2-20: Besondere Anforderungen an Kleindrosseln

EN 61071: 2007 Kondensatoren der Leistungselektronik EN 61000-6-2 (EMC Immunity for industrial environments) EN 61000-6-3 (Emission for residential, commercial and light

industrial environments) Technical file: TR080115-FN341x-P1 ECOsine™ FN 3410 and FN 3412 filters are passive harmonic filters designed for the operation on the input (grid) side of power electronic equipment with 6-pulse rectifier front ends in balanced three-phase power systems, like typically used in AC or DC motor drives and high power DC supplies.

The installation instructions are integrated part of the product.

The product shall exclusively be used in the above-mentioned application according to the installation instruction.

Luterbach, [currently in preparation]

Schaffner EMV AG

Fabian Beck, VP Research & Development

[Signature]

ECOsine™ – Passive Harmonic Filters

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